HVAC Portfolio Efficiency
HVAC Portfolio Efficiency
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Driving Lean Transformation to Increase Line Efficiency from 69% → 83%
Driving Lean Transformation to Increase Line Efficiency from 69% → 83%
The HVAC assembly line operated at 69% efficiency, causing production delays, increased operational costs, and reduced competitiveness in the mining and industrial HVAC segment.
The lack of standardized workflows, inefficient layout, and unclear KPIs further limited the line’s ability to scale or respond to customer demand.
I Led a Lean Six Sigma DMAIC initiative to increase efficiency by at least 10 points.
The solution focused on:
Mapping the end-to-end workflow to identify bottlenecks
Redesigning the line layout and material handling flows
Establishing clear KPIs and operating standards
Using SAP data to validate decisions and quantify improvements
Implementing visual management and ongoing monitoring tools
Cross-Functional Coordination
Cross-Functional Coordination
Trained operators, technicians, and supporting teams.
Aligned engineering, manufacturing, and quality SMEs to ensure seamless prototyping-to-serial transition.
Process Excellence
Process Excellence
Implemented Kanban, JIT, and Lean Six Sigma techniques across the line.
Defined SOPs, work instructions, and end-to-end process documentation.
Governance & Transfer Model
Governance & Transfer Model
Designed and deployed the full transfer-to-production methodology.
Ensured compliance with customer and internal standards from Spain and Australia.
Process Excellence
Process Excellence
Developed a Value Stream Map (VSM) to highlight systemic inefficiencies.
Defined KPIs and measurable success criteria.
Redesigned the line layout to reduce motion, waiting time, and material waste.
Optimized material flow and replenishment processes.
Analyzed SAP operational data to validate cycle times and productivity levels.
Governance & Transfer Model
Governance & Transfer Model
Conducted full DMAIC cycle.
Updated all documentation: SOPs, PRs, and One-Point Lessons.
Deployed dashboard-based monitoring for continuous control.
Impact
Impact
Efficiency improved from 69% → 83%.
Efficiency improved from 69% → 83%.
100% of SOP, PR, and OPL documentation updated.
100% of SOP, PR, and OPL documentation updated.
100% KPI dashboards deployed and adopted.
100% KPI dashboards deployed and adopted.
Project Documentation
Project Documentation
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